International Journal on Interactive Design and Manufacturing (IJIDeM)

https://doi.org/10.1007/s12008-019-00592-5

ORIGINAL PAPER

Analytical and numerical analysis of the tire tightening system

of a cement kiln
S. El Fakkoussi1 · H. Moustabchir2 · A. Elkhalfi1 · C. I. Pruncu3,4

Received: 16 May 2019 / Accepted: 25 May 2019

© The Author(s) 2019

Abstract
The rotary cement kiln forms a major part of any cement works. The kiln is a large cylindrical structure where the raw
materials are brought together and heated to form clinker, the base material of cement. To ensure production plant reliability
and product quality an understanding and evaluation of the kiln design parameters is of paramount importance. This paper
presents a solution for evaluating the mechanical strength of the shims, vital components in the drive system. These parts
transmit the rotational drive to the kiln drum, and are subject to large mechanical and thermal stresses. The results of this
study enable a reliable plan for preventive maintenance of the kiln furnaces to be developed. The methodology employed
detects the mechanical and thermal stresses distributed on the surface of the shim while the working cycle are active, and uses
both mechanical theory and numerical simulation by the Finite Elements Method (FEM) under the ANSYS software. The
numerical results provide an authoritative guide to the accurate prediction of the optimal preventative maintenance interval
for the rotary cement kilns drive element.

Keywords Rotary kiln · Maintenance time · Binder · Casing · Numerical simulation · ANSYS

1 Introduction of the move to a sustainable development strategy aimed at

In recent years, the cement industry has made significant
investments in increasing and diversifying production in
order to satisfy growing market demand. Lafarge Holcim
[1], the international leader in materials construction, is part
B C. I. Pruncu
c.pruncu@imperial.ac.uk
S. El Fakkoussi
said.elfakkoussi@gmail.com
H. Moustabchir
hmoustabchir@hotmail.com
A. Elkhalfi
aelkhalfi@gmail.com
1 Mechanical Engineering Laboratory Faculty of Science and
Technology, Fez, Morocco
2 Laboratory of Systems Engineering and Applications (LISA),
National School of Applied Sciences of Fez, Fez, Morocco
3 Department of Mechanical Engineering, Imperial College
London, Exhibition Road, London SW7 2AZ, UK
4 Department of Mechanical Engineering, School of
Engineering, University of Birmingham, Birmingham B15
2TT, UK
reducing environmental impact in the face of strong compe-
tition and the increasing demand for building materials. They
produce cement that is a hydraulic binder, a mineral powder
of greyish appearance, obtained by grinding and baking a
mixture of limestone and clay at 1450 °C. The main prod-
uct (material) of this process, called clinker, is formed of a
combination of lime, silica, alumina and ferric oxide.
As a general rule, the furnace comprises a group of
pipelines (that are in permanent rotation allowing the dis-
placement of the material) made of low-carbon steel con-
nected end to end, forming a global entity called a casing
(shell). The casing (shell) of the rotary furnace consists of
several sections of different sizes assembled by welding and
coated with refractory bricks. The assembly is supported and
driven in rotation by three roll riding tyre, or hoops, as is
depicted on the Fig. 1.
The furnace is a massive and strong structure but cannot
tolerate any type of geometrical defects. In fact, the biggest
furnaces are most susceptible. To allow for thermal expansion
and mechanical loading and deformation a shim element is
fitted between the riding tyre and the casing (shell). This shim
element is liable to damage due to the thermal expansion of

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Fig. 1 A typical rotary kiln
the elements (casing and riding tyre), but also because of the
weight of the kiln and its contents.
Indeed, the rotation of the riding tyre may cause its wear
as well as that of the wedges, shims and lateral hoops (see
Fig. 2). When the wear of the shims becomes too great, the
casing (shell) may become critically deformed, which causes
a loss of the bricks [2]. The shims are evenly distributed
around the casing (shell) and serve to hold the riding tyre
in a fixed rotational path around the furnace. They must,
however, ensure a functional clearance of 11 mm, to prevent
thermal expansion of the casing (shell) generating permanent
deformation.
In the case examined, the bandage riding tyre currently
contains a transverse crack that extends almost to the two
ends of the riding tyre. The shims, on the other hand, tend to
detach from the casing (shell) and to destabilize the rotation
of the riding tyre. Thus, the dimensions of the shims, their
method of attachment and their component material must
be carefully studied in order to avoid distortion of the shell
Fig. 2 The riding tyre and
timing system during
deformation of shim parts
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International Journal on Interactive Design and Manufacturing (IJIDeM)
that may be critical to riding tyre stability and have a further
impact on the fracture resistance of the structure. The finite
element software ANSYS was engaged to analyse the struc-
ture stress and the thermal stress distribution in the cylinder.
The analysis results are helpful in the design and optimiza-
tion of the rotary kiln cylinder [3–5]. The predicted results
of outer kiln wall temperature agree well with measurements
[6]. The results assist in maintaining the reliability of the
cement kiln so as to ensure its continuous operation 24 h a
day [7].
2 Component geometry and mechanical
characteristics
2.1 Geometry
A rotary kiln is the key rotating machine used in the pro-
duction of cement. Similar large rotating machines are used
in other chemical and metallurgical industries. The tubular
geometry of the furnace is represented in Fig. 3. The overall
dimensions of the kiln are length of 63 meters and internal
diameter 4 meters (Table 1). In evaluating the operation state
of the kiln, it is important to measure the straightness devi-
ation and surface deformation of kiln cylinder as they are
important physical indictors of kiln condition [8].
In order to determine globally the reaction forces gener-
ated on the supports, it was used the Resistance Calculation
Software (RDM6). A sketch of these reaction and forces are
plotted in Fig. 4.
In this study, we consider the performance of the shim ele-
ment used to transmit forces between the kiln drum and the
supporting hoops. The geometry of the shim component was
International Journal on Interactive Design and Manufacturing (IJIDeM)

Fig. 3 A simplified arrangement

of the furnace geometry

Table 1 Geometric and mechanical characteristics of the Kiln 3 Assessment of working conditions
Kiln length 63 m
Kiln internal diameter 4.00 m 3.1 Analytical evaluation
Kiln external diameter 4.15 m
3.1.1 Mechanical and thermal study
Angle inclination 1.718°
Rotation Frequency 3 T/min
The cylindrical kiln structure is a loose fit within the kiln tyre,
Number of supports 3
and can be treated as a simply supported beam. The kiln shell
Weight of rotating cement 136.96 T
at inlet and kiln outlet are unsupported. Reaction at the tyre
Total weight oven steel 184.49 T
under loading is considered [10]. The force applied to the
Total weight of kiln bricks 371.41 T
shim and the reaction forces (Table 3) at the bearings can be
Inner radius of the ring 2132 mm
calculated using the following formula [11, 12].

represented by a 3D CAD model developed in SolidWorks.
This model showing the geometrical and dimensional repre-
sentation is shown in Fig. 5. This model was ported into the
ANSYS F.E. package in order to evaluate the shim perfor-
mance under external loading conditions.
2.2 Material
The shim component is made of a material A42CP [9]. The
mechanical characteristics are given in the Table 2.
2 · R2 · cos(ϕ)
Q (1)
Rπ
with (ϕ)  5π /6, R inner radius of the ring.
Figure 6 shows general arrangement of tyre and rollers. Q
and R2 respectively are the force applied to the shim and the
reaction force at bearing 2 of the furnace.
The resulting mechanical and thermal forces acting on the
shims are represented in Fig. 7.
A simplified loading model was generated: the cement
mixture is assumed to be symmetrically distributed around

Fig. 4 Distribution of forces in the oven applied to the supports

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Fig. 5 Geometrical sketch of a shim, values in mm

Table 2 Mechanical characteristics of A42CP [9]

Material properties Values

Young modulus 210,000 MPa

Poisson ratio 0.3
Yield strength 250 MPa
Tensile strength 420 MPa
Density 7850 kg/m3

Table 3 Forces determined for the kiln supports

Reaction forces (R1 ) 2.23*103 kN
at (X  11 m)
Reaction forces (R2 ) 4.84*103 kN
at (X  38 m)
Reaction forces (R3 ) 0.76*103 kN
at (X  59 m)
Torque (X  15 m) 670.23 kN m

Fig. 6 Shows general arrangement of tyre and rollers. Q and R2 respec-

tively are the force applied to the shim and the reaction force at bearing
the vertical axis of the kiln. This means that load weight of two of the furnace
material is evenly distributed over each roller [11].
The mechanical and thermal loads applied to the shim are:

Q The weight of the tyre that translates as an axial force

σ1  (2) over the upper wing of the shim generates a stress equal
S
σ2  1.11 MPa.
where S load bearing area of shim, Q load on the shim (Eq. 1). The shim is in contact with the ring, on the ring side
For the case considered: temperature is around 275 °C. It has to be measured using
Q  1440 KN With S  723 ∗ 382 and S  276,186 ∗ infrared thermometer and with the welded-on the shell at a
103 mm2 . temperature of 300 °C. The temperature difference is gen-
Thus, the stress applied to the outer surface of the shim, erated due of thermal stress that generates a loading of
its equal to a value σ1  5.21 MPa. σ3  173.25 MPa (Fig. 8).

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International Journal on Interactive Design and Manufacturing (IJIDeM)

Fig. 7 Representation of forces

applied on the shim

Fig. 8 Temperature distribution

at Shim level

The result confirms that the minimum criteria of mainte-

800 MPa < R M < 1300 MPa; σ D 
nance can be predicted successfully.
 R M 0.57 − 1.2 ∗ 10−4 R M (6)
σmax (max(σ1 , σ2 , σ3 )) < Re (3)  
1300 MPa < R M ; σ D  R M 0.56 − 1.4 ∗ 10−4 R M
σmax  173.25 MPa is maximum stress applied to the shim,
Re  250 MPa is the limit of elasticity of material A42CP. σ D  210.05 MPa (7)

3.1.2 Fatigue study
Each shim, when performing a single turn of the furnace, is
subjected to intermittent compression stress between the tire
and the casing (shell) because it is getting in the contact with
the roller 1 and then with the roller 2.
There, σ  a and σ  m are the equivalent constraints of Von
Misses developed from the alternating and average compo-
nents, ascribed as:
 
σa  σ1 , σa  5.21 MPa
 
 
σm  σ32 + 3σ22 , σm  173 MPa
 
σ  σm + σa · sin(ω · t)
Further, the endurance limit (σ D ) that is generated in the
rotational bending were calculated integrating some assump-
tion that was developed by using specific equations, such as:
 
R M < 800 MPa; σ D  R M 0.56 − 1.4 ∗ 10−4 R M
(5)
However, in order to determine the structure fatigue life
accurately it requires carefully examination of all stress
states involved in the process. Further, variations can occurs
because of geometry imperfection (notches, holes…) that one
generate reduction of the fatigue limits. A paramount impor-
tance should be dedicated to prediction of life expectancy in
relationship to its structural details.
Therefore, were introduced some correction factors such
as [13]:

σ D  ka × kb × kc × kd × σ D (8)
σ D is the endurance limit corrected, ka surface finish factor,
kb size effect factor, kc reliability factor, kd factor of the effect
(4) of temperature.

σ D  ka × kb × kc × kd × σ D

σ D  0.72 × 0.75 × 0.897 × 0.6 × 210.5

σ D  61.17 MPa

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 International Journal on Interactive Design and Manufacturing (IJIDeM)

Fig. 9 Shim model showing the

FE mesh used in the analysis

Here, the security factor were determined using several than 15 years with will provide benefits as well in terms of
methods: economic aspects.

• method Goodman [14]:

   3.2 Numerical simulation

σa σm
FS  1  + (9)
σ D Rm Verification of the results obtained by theoretical calculation
is an important and necessary phase. Hence the importance of
F S  1.68 numerical simulations which are able to exploit the increas-
ingly powerful processors and simulation software available.
• method Soderbergh [14]:
By undertaking a check under ANSYS software it is possi-
  
 ble to analyse and visualise the concentration of stresses and
σa σm
FS  1  + (10) identify the most stressed parts. This allows the modifications
σ D Re necessary to ensure the proper functioning of this system to
F S  1.14 be determined and evaluated.
Figure 9 shows the finite element model adopted for solv-
• method gerber [14]: ing the problem. This contains 99,499 nodes and 62,424
 ⎛    2 ⎞
elements.
σ σm ⎠
F S  1 ⎝ a + (11)
σD Rm
3.2.1 Results
F S  2.28
Numerical analysis was carried out using ANSYS soft-
In the end, were calculated the life span of the shim in ware [15]. The numerical analysis represents a solution
terms of the number of cycles (hours). Later on, it was fitted more realistic of a kiln-tyre system that may reveal smaller
against the maximum stress using the Wöhler curve [13] and compressive stresses in the contact region compared to the
the results were obtained as: analytical predictions [16]. After the 3D geometry model is
built (see for reference Fig. 5), it can be imported into the
NC ycl 1 tour/min analysis module to establish the finite element model. The
t(h)  × (12)
T (tr /min) 60 min/h finite element model mainly comprises the geometric model
2.5 × 107 cycl 1 tour/min containing the parts of a shim body, the definition of material
t(h)  × ; t  1.38105 h parameters, and the finite element mesh generation [17].
3 60 min/h
The loading condition considered is that shown in Fig. 7.
The actual working condition permits to estimate a safety The thermal condition imposed is that where the shim inner
life of the entire structure for around 15 years. Moreover, surface reach around 300 °C, with all other surface being in
taking into account that the elastic limit is more the 15% free air at 275 °C.
higher compare to the endurance limit determined; in real- After analysing the result obtained by the three-
ity the lifespan of this component can be extended to more dimensional numerical model embedded into ANSYS it is

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International Journal on Interactive Design and Manufacturing (IJIDeM)
Fig. 10 A picture of distribution
of thermo mechanical stresses in
the shim
Fig. 11 A picture of the
displacements along the Y-axis
in the shim/hold
possible to verify the validity of the stresses used to predict
the maintenance period.
Figure 10 shows the maximum loading condition on shim
part. The influence of mechanical stresses is low compared
to thermal stresses. The equivalent maximum stress of Von
Mises σV M  226.44 MPa and the value of the analytical
method σmax  173.25 MPa remains well below the elastic
limit Yield Stress of Re  250 MPa.
The resulting displacements of the shim are shown in
Fig. 11. Displacements along the Y axis are low at the bot-
tom of the shim due to fixation and increase towards the head
where the value at the highest points of the upper part of the
shim is equal to 0.031 mm. Remember that the calculation of
the displacement in the hold is done by the numerical method
(i.e. the software finite elements ANSYS).
4 Conclusion
A reliable calibration analysis of a system model was done.
The results obtained by analytical and numerical methods are
comparable and reflect the documented results from experi-
mental and theoretical engineering judgment and experience
[18]. The strategy applied has advantages due to the use
of a detailed (3D) FEA model to reflect the actual service
conditions and geometry. As a result of this work, it is fur-
ther proposed to study the weld bead between the shims
and the shroud. The objective is to deduce the constraints
applied to the shim and to model the operating conditions of
within the context of determining the preventive maintenance
requirements of the cement kiln. And to add a complemen-
tary assessment to the entire plant will be worth to impose an
extended plan that should incorporate a validated technique
used to build extremely reliable devices based on the opti-
mal plan by estimation a constant-stress of an accelerated life
tests [19].
Open Access This article is distributed under the terms of the Creative
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